Domestic appliance access panel

ABSTRACT

An access panel is disclosed for extending across a lower frontal section of a domestic appliance positioned on a surface. The access panel includes, a substantially rigid middle portion having a top edge and a bottom edge, a flexible top portion attached along at least a portion of the top edge of the substantially rigid middle portion for positioning adjacent the lower frontal section of the domestic appliance, and a flexible bottom portion attached along at least a portion of the bottom edge of the substantially rigid middle portion for positioning adjacent the surface. A leveling bracket is disposed adjacent the lower frontal section of the domestic appliance. The leveling bracket has a slot for receiving at least one tab element of the access panel for retaining the access panel across the lower frontal section of the domestic appliance, the tab element being moveable within the slot between a first position and a second position for adjusting the height of the flexible bottom portion in relation to the surface.

FIELD

This invention relates generally to an access panel for domestic appliances. More specifically, this invention relates to a thermoplastic access panel having a rigid middle portion, one or more flexible edge portions, and a self-leveling bracket for providing an access panel that is economical to manufacture and install.

BACKGROUND

In dishwashers and other related domestic appliances, the appliance is often supported above the floor such that a recess or toespace is provided in the lower frontal section of the appliance. The toespace is generally a few centimeters above the floor and extending rearward another couple of centimeters. The appliance also often has various electrical components stored just beyond the toespace. The lower frontal sections of the appliances and its associated electrical components are often protected by an access panel (also known as a kick plate). The access panel performs various functions such as protecting the appliance from debris and damage to the electrical components, dampening the noise produced by the electrical components, and providing a more pleasing aesthetic appearance.

Access panels in the past have been made of metal. However, these metal access panels are disadvantageous because they are difficult to install due to the various dimensions and imprecise nature of the toespaces during installation. Adding to the difficulty in installation, fixing the access panel to the appliance requires screwing threaded fasteners through the upper and lower portions of the access panel into the outer frame of the appliance. This type of attachment is difficult due to the locations of the fastening positions being hard to reach without specially formed tools, and installation could only be done on site after the dishwasher had already been installed at its desired location. Furthermore, to dampen the noise produced by the electrical components, the metal access panels must include insulating layers between the access panel and the appliance.

Accordingly, it is desirable to provide an access panel that easier to install and/or can be installed before shipping of the dishwasher. Also, it is desirable to provide an access panel that is more economical to manufacture.

SUMMARY

Embodiments of the invention described herein pertain to an access panel for extending across a lower frontal section of a domestic appliance positioned on a surface. In one embodiment, the access panel includes, a substantially rigid middle portion having a top edge and a bottom edge, a flexible top portion attached along at least a portion of the top edge of the substantially rigid middle portion for positioning adjacent the lower frontal section of the domestic appliance, and a flexible bottom portion attached along at least a portion of the bottom edge of the substantially rigid middle portion for positioning adjacent the surface. The access panel may also include a mount formed on the access panel for mounting the access panel across the lower frontal section. In preferred embodiments, the mount includes at least one tab element attachable to the substantially rigid middle portion and a leveling bracket having a slot for receiving the at least one tab element and for retaining the access panel across the lower frontal section of the domestic appliance, the tab element being moveable within the slot between a first position and a second position for adjusting the height of the flexible bottom portion in relation to the surface.

In preferred embodiments, the substantially rigid middle portion and the flexible top and bottom portions are thermoplastic. Preferably the thermoplastic is a co-extruded integral combination of rigid and flexible polyvinyl chloride.

In other embodiments, the access panel includes a substantially rigid portion having a top edge and a bottom edge, the top edge for positioning adjacent the lower frontal section of the domestic appliance and the bottom edge for positioning adjacent the surface. A flexible portion is attached along at least a portion of at least one of the top edge and bottom edge of the substantially rigid portion, and the flexible portion is to be disposed between at least one of the top edge of the substantially rigid portion and the lower frontal section of the domestic appliance and between the flexible bottom portion and the surface.

In another embodiment of the invention, the access panel includes a substantially rigid portion including at least one tab element, the substantially rigid portion having a top edge and a bottom edge. The top edge is for positioning adjacent the lower frontal section of the domestic appliance and the bottom edge is for positioning adjacent the surface. A leveling bracket is disposed adjacent the lower frontal section of the domestic appliance and has a slot for receiving the tab element and retaining the substantially rigid portion across the lower frontal section of the domestic appliance. The tab element is moveable within the slot between a first position and a second position for adjusting the height of the bottom edge of the substantially rigid portion in relation to the surface.

In preferred embodiments, the slot includes a first slot portion for allowing for insertion of the tab element within the slot, a second slot portion for the preventing of the bottom edge of the substantially rigid portion from contacting the surface during shipping and installing of the dishwasher, and a third slot portion for the adjusting of the height of the bottom edge of the substantially rigid portion in relation to the surface after the dishwasher is installed. The tab element is moveable within the slot between the first slot portion, the second slot portion, and the third slot portion. A flexible portion may also be attached along at least a portion of the top edge of the substantially rigid portion for positioning between the lower frontal section of the domestic appliance and the top edge of the substantially rigid portion.

BRIEF DESCRIPTION OP THE DRAWINGS

Further advantages of the invention are apparent by reference to the detailed description in conjunction with the figures.

FIG. 1 depicts a perspective view of a dishwasher and associated access panel;

FIG. 2 depicts a side view of an access panel according to an embodiment of the present invention;

FIG. 3 depicts a perspective front view of an access panel including a leveling bracket according to an embodiment of the present invention;

FIG. 4 depicts a perspective rear view of the access panel of FIG. 3 according to an embodiment of the present invention;

FIG. 5 depicts a rear view of the access panel of FIGS. 3 and 4 according to an embodiment of the present invention;

FIG. 6 depicts an exploded view of a leveling bracket according to an embodiment of the present invention;

FIG. 7 depicts a leveling bracket slot and possible tab element positions according to an embodiment of the present invention; and

FIGS. 8A-8D depicts alternate embodiments of a tab element according to various embodiments of the present invention.

DETAILED DESCRIPTION

Referring to FIG. 1, a dishwasher 10 is shown having a washing chamber 12 or tub supported by a frame including a top wall 14, bottom wall 16, rear wall 18, and two opposing side walls 20 and 22. A front access door 24 is hinged along the bottom wall 16 and provides entry into the washing chamber 12 of the dishwasher 10 for loading and unloading dishes.

The bottom wall 16 of the dishwasher 10 is spaced above a floor or other mounting surface to provide a recess or toespace 26 at a lower frontal section 28 of the dishwasher 10. Behind the toespace 26 and below the bottom wall 16 of the dishwasher includes an electrical panel 30 for storing various electrical and mechanical components of the dishwasher such as the motor, pump, and water valves. An access panel 32 is provided to extend across the lower frontal section 28 of the dishwasher 10 and toespace 26 to prevent damage to the various components, limit debris and dust from entering the dishwasher 10, dampen the sound emitting from the motor, and to provide a more pleasant and finished aesthetic appearance. The access panel 32 is attached to the dishwasher 10 so that a top edge 34 of the access panel 32 is disposed adjacent the lower frontal section 28 and a bottom edge is disposed adjacent the floor or mounting surface.

As depicted in FIG. 2, an access panel 32 according to one embodiment of the present invention includes a substantially rigid middle portion 38 having a top edge 34 and a bottom edge 36. The middle portion 38 may be one vertical panel, but, as shown in FIG. 2, is preferably two vertical panels 40 and 42 connected by an angled panel 44. The angled panel 44 is preferably angled between 30° and 60° so that the bottom edge 36 projects outwardly from the top edge 34. In preferred embodiments, the total height of the middle portion is about 128 mm. However, the height can vary according to the size of the toespace 26 in which the access panel 32 needs to cover.

Attached to the top and bottom edges 34 and 36 of the substantially rigid middle portion 38 are respective top and bottom flexible portions 46 and 48. The flexible top portion 46 is attached along at least a portion of the top edge 34 of the substantially rigid middle portion 38 for positioning against the lower frontal section 28 of the dishwasher 10 when the access panel 32 is installed. The flexible bottom portion 48 is attached along at least a portion of the bottom edge 36 of the substantially rigid middle portion 38 for positioning against the mounting surface after the access panel 32 is installed on the dishwasher 10. The top and bottom portions 46 and 48 are flexible in order to more easily and accurately conform to the lower frontal sections 28 of dishwashers and mounting surfaces even where there are variations in the heights of the toespaces 26 of different installed dishwashers.

In preferred embodiments, the access panel 32 is an extruded thermoplastic material, such as polypropylene, polyvinyl chloride (PVC) and PVC alloys, or any other suitable thermoplastic. The access panel 32 is preferably co-extruded PVC with the rigid PVC of the middle portion 38 abutting the flexible PVC of the top and bottom portions 46 and 48. When the PVC cools after the extrusion process, the rigid middle portion 38 having flexible top and bottom portions 46 and 48 attached along its top and bottom edge 34 and 36 is provided as one integrally structured access panel 32.

Thermoplastic is an ideal solution for the access panel 32 because it is not damaged by moisture, it is durable, resistant to flame spread (as characterized by its UL ratings, e.g. 94-VO), ecologically friendly, easy to install, does not scratch other parts, and is economical to manufacture. Furthermore, studies have shown that a thermoplastic access panel 32 works as well or better to reduce noise from the electrical components of the dishwasher as compared to metal access panels with sound dampening foam.

While the access panel 32 is described above as having top and bottom flexible portions 46 and 48, the access panel could also have only one flexible portion attached to either the top or bottom edge 34 or 36 of the substantially rigid middle portion 38. Furthermore, the height of the flexible top and bottom portions 46 and 48 can vary. In preferred embodiments, the flexible top portion 46 is about 25 mm and the flexible bottom portion 48 is about 38 mm. In other embodiments of the present invention, as described below, the access panel 32 may include the rigid middle portion 38 without either of the flexible top and bottom portions 46 and 48, with one of the flexible portions, or with both flexible portions 46 and 48.

Referring to FIGS. 3-7, according to another embodiment of the invention, the access panel 32 includes leveling brackets 50 for attaching the access panel 32 adjacent the lower frontal section 28 of the dishwasher 10 and for adjusting the height of the access panel 32 with respect to the mounting surface. In this embodiment, the substantially rigid middle portion 38 of the access panel 32 includes tab elements 52 attached to the rear surface 54 of the middle portion 38 preferably adjacent its side edges 56. The access panel 32 may then be mounted to the dishwasher 10 or to a cabinet in which the dishwasher 10 rests by mating the tab elements 52 with the leveling brackets 50 that are mounted or welded to the dishwasher 10 or cabinet near the appliance's toespace 26.

In preferred embodiments as depicted in the exploded views of FIGS. 6 and 7, each of the leveling brackets 50 includes slots 58 for receiving the tab elements 52 of the access panel 32. The slots 58 in the leveling brackets 50 are preferably an upside down “J” shape. At a first slot portion 60, the top part of the slot 58 having a greater width, the tab element 52 may be inserted into the slot 58 at an assembly position for attaching the access panel 32 to the dishwasher 10. The slot 58 further includes a second slot portion 62 in which the tab element 52 may be moved from the assembly position to a shipping position. The second slot portion 62 is the shorter length side of the upside down “J,” which prevents the access panel 32 from dragging or contacting the floor or mounting surface during transport or installation of the dishwasher 10. The third slot portion 64 includes the longer length side of the upside down “J.” In the third slot portion, the tab element 52 may be moved to an installed position. In the installed position, the tab element 52 is able to move freely within the third slot portion 64 to adjust the height of the access panel 32 with respect to the mounting surface.

The tab element 52 and leveling brackets 50 may also include means for locking the tab element 52 in position in the desired portion of the slot 58. For example the tab element 52 may be inserted into the slot 58, moved to the correct slot portion such as the installed position, and then tightened by screwing the tab element 52 further into the access panel 32. Thus, the tab element 52 is pressed against the leveling bracket 50 to prevent any further movement of the access panel 32 until the tab element 52 is unscrewed or loosened.

In an alternate embodiment, the tab element 52 may be attached to the access panel 32 after the leveling brackets are aligned with the access panel. In this embodiment, the access panel 32 includes an aperture for receiving the tab element 52. After the access panel 32 is aligned with the slots 58 of the leveling bracket 50, the tab elements 52 are inserted through the slots 58 into the aperture for securing the access panel to the lower frontal section 28 of the dishwasher 10.

FIGS. 8A-8D depict alternate embodiments of various tab elements 52 that may be used to mount the access panel 32 to the dishwasher 10 by mating the tab element 52 to a bracket attached to the appliance or associated cabinet.

While the various embodiments of the access panel 32 have been described above with respect to a dishwasher 10, the features of the access panel 32 may be utilized with any other domestic appliances such as a refrigerator, oven, washer and dryer, etc.

The foregoing description of preferred embodiments for this invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the invention and its practical application, and to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention. 

1. An access panel for extending across a lower frontal section of a domestic appliance positioned on a surface, the access panel comprising: a substantially rigid middle portion having a top edge and a bottom edge; a flexible top portion attached along at least a portion of the top edge of the substantially rigid middle portion for positioning adjacent the lower frontal section of the domestic appliance; and a flexible bottom portion attached along at least a portion of the bottom edge of the substantially rigid middle portion for positioning adjacent the surface.
 2. The access panel of claim 1 wherein the substantially rigid middle portion and flexible top and bottom portions are thermoplastic.
 3. The access panel of claim 2 wherein the thermoplastic comprises extruded polyvinyl chloride.
 4. The access panel of claim 3 wherein the substantially rigid middle portion and the flexible top and bottom portions is a co-extruded integral combination of rigid and flexible polyvinyl chloride.
 5. The access panel of claim 1 further comprising a mount formed on the access panel for mounting the access panel across the lower frontal section.
 6. The access panel of claim 1 further comprising: at least one tab element attachable to the substantially rigid middle portion; and a leveling bracket disposed adjacent the lower frontal section of the domestic appliance having a slot for receiving the at least one tab element and for retaining the access panel across the lower frontal section of the domestic appliance, the tab element being moveable within the slot between a first position and a second position for adjusting the height of the flexible bottom portion in relation to the surface.
 7. An access panel for extending across a lower frontal section of a domestic appliance positioned on a surface, the access panel comprising: a substantially rigid portion having a top edge and a bottom edge, the top edge for positioning adjacent the lower frontal section of the domestic appliance and the bottom edge for positioning adjacent the surface; and a flexible portion attached along at least a portion of at least one of the top edge and bottom edge of the substantially rigid portion, the flexible portion to be disposed between at least one of the top edge of the substantially rigid portion and the lower frontal section of the domestic appliance and between the flexible bottom portion and the surface.
 8. The access panel of claim 7 wherein the substantially rigid portion and the flexible portion are thermoplastic.
 9. The access panel of claim 8 wherein the thermoplastic comprises extruded polyvinyl chloride.
 10. The access panel of claim 9 wherein the substantially rigid portion and the flexible portion is a co-extruded integral combination of rigid and flexible polyvinyl chloride.
 11. The access panel of claim 7 further comprising: at least one tab element attachable to the substantially rigid middle portion; and a leveling bracket disposed adjacent the lower frontal section of the domestic appliance having a slot for receiving the at least one tab element and for retaining the access panel across the lower frontal section of the domestic appliance, the tab element being moveable within the slot between a first position and a second position for adjusting the height of the flexible bottom portion in relation to the surface.
 12. An access panel for extending across a lower frontal section of a domestic appliance positioned on a surface, the access panel comprising: a substantially rigid portion including at least one tab element, the substantially rigid portion having a top edge and a bottom edge, the top edge for positioning adjacent the lower frontal section of the domestic appliance and the bottom edge for positioning adjacent the surface; and a leveling bracket disposed adjacent the lower frontal section of the domestic appliance having a slot for receiving the tab element and retaining the substantially rigid portion across the lower frontal section of the domestic appliance, the tab element being moveable within the slot between a first position and a second position for adjusting the height of the bottom edge of the substantially rigid portion in relation to the surface.
 13. The access panel of claim 12 wherein the tab element is moveable within the slot to a third position for preventing the bottom edge of the substantially rigid portion from contacting the surface during shipping and installing of the dishwasher.
 14. The access panel of claim 13 wherein the slot includes a first slot portion for allowing for insertion of the tab element within the slot, a second slot portion for the preventing of the bottom edge of the substantially rigid portion from contacting the surface during shipping and installing of the dishwasher, and a third slot portion for the adjusting of the height of the bottom edge of the substantially rigid portion in relation to the surface after the dishwasher is installed, and wherein the tab element is moveable within the slot between the first slot portion, the second slot portion, and the third slot portion.
 15. The access panel of claim 12 further comprising a flexible portion attached along at least a portion of the top edge of the substantially rigid portion for positioning between the lower frontal section of the domestic appliance and the top edge of the substantially rigid portion.
 16. The access panel of claim 15 wherein the substantially rigid portion and the flexible portion are thermoplastic.
 17. The access panel of claim 16 wherein the thermoplastic is a co-extruded integral combination of rigid and flexible polyvinyl chloride. 